TECHNICAL INSTRUCTIONS FOR SAFETY RECALL F0I EV GATEWAY CONTROL ECM SOFTWARE UPDATE MY RAV4 EV

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TECHNICAL INSTRUCTIONS FOR

SAFETY RECALL F0I

EV GATEWAY CONTROL ECM SOFTWARE UPDATE

2012-2014 MY RAV4 EV

The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this repair are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this repair are required to currently hold the following certification levels and attended the following instructor led class:

• Hybrid Expert Technician

• Master Technician

• Master Diagnostic Technician

• Rav4 EV New Model Technical Introduction (Course 012D- Instructor Led)

It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times.

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I. OPERATION FLOW CHART

Verify Vehicle Eligibility 1. Check the TIS Vehicle Inquiry

System.

No further action required.

Not Covered

Covered

Campaign complete.

Return the vehicle to the customer.

Perform Health Check and Confirm

ECM Calibration New Calibration

Old Calibration

Reflash ECM and Install Authorized Modification Label

Confirm Repair Quality

This campaign only covers the ECM Reflash to address traction motor software

concern.

This campaign does not cover the replacement of any components.

IDENTIFICATION OF AFFECTED VEHICLES

NOTE:

• Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall and that the campaign has not already been completed prior to dealer shipment or by another dealer.

• TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected or was completed by another dealer.

II. PREPARATION

1. PARTS

Part Number Part Description Quantity

00451-00001-LBL* Authorized Modification Label 1

*Labels can be ordered in packs of 25 from the MDC through the Dealer Daily Website

2. TOOLS, SUPPLIES & EQUIPMENT

• Techstream 2.0 ( Software 10.10.018 or Higher)

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III. BACKGROUND

In the involved RAV4 EV’s, components in the Electric Vehicle Traction Motor Assembly, which is part of the propulsion system, may cause the vehicle to shift to “neutral” due to a software issue. This condition will also trigger a “Check EV System” warning message on the instrument panel and turn on a malfunction indicator lamp. If the vehicle shifts to “neutral”, this will result in a complete loss of drive power, which can increase the risk of a crash.

IV. CHECK POWER MANAGEMENT ECU CALIBRATION

1. CONFIRM ECU CALIBRATION ID a) Perform a health check

b) Confirm the calibration ID in the ECM.

System Cal ID Update

EV 896B34201300 Yes**

896B54201100 Yes**

Cruise Control* - -

Electronic Propulsion Control System

1.3.83 Yes

2. CONFIRM ELECTRONIC PROPULSION GATEWAY CALIBRATION.

a) Check Module Calibration ID

Module Previous Calibration New Calibration

Tesla Electronic Propulsion

Gateway Control Module 1.3.83 1.3.101

b) If Module Calibration has been reflashed Campaign is Complete. If reflash has not been complete go to step V.

THE EV POWER MANAGEMENT ECU MUST BE REFLASHED BEFORE THE ELECTRONIC PROPULSION GATEWAY CONTROL MODULE OTHERWISE ECU DAMAGE CAN OCCUR.

* Cruse Control module is not a factor in this campaign.

** The EV Power Management ECU may have been reflashed prior to preforming this campaign. If it has been updated the update box will display “No”.

Step

1

2

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V. REFLASH TESLA ELECTRONIC PROPULSION GATEWAY CONTROL MODULE

• If the Techstream does not have sufficient battery power the reflash will fail.

• Confirm the DLC3 cable is in good condition before attempting reflash.

1. Follow Procedure Outlined in RAV4 EV ECU Flash Reprogramming Procedure (T-SB-0043-13)

NOTICE: The warning message below is referring to the High Voltage Traction Battery charger. The 12v GR8 must be connected during reflash.

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2. Complete Reflash Procedure

a) Once reflash is complete Click OK.

b) Disconnect the Tesla Powertrain Diagnostic Cable and close the program.

c) Connect the Techstream DLC3 cable to the OBDII connector under the dash.

d) Perform a Health Check to confirm the firmware was installed correctly and to check for DTCs.

e) Clear All DTC’s.

f) Cycle the Power button to the Ignition on not ready state 5 times within 30 seconds.

g) Test drive vehicle.

3. Attach the authorized vehicle modification label a) Fill out the label.

b) Affix the label to the under-side of the hood.

1 Replacement Power Management Control ECU Part Number 2 New Calibration ID of Power

Management Control ECU

3 Dealer Code

4 Date Completed

5 Safety Recall Designation: F0I

NOTE : Wait 60 – 90 seconds for ink to set before handling.

◄ VERIFY REPAIR QUALITY ►

− Confirm the ECU Calibration has been updated successfully

− Confirm that an Authorized Modification Label has been installed

− If you have any questions regarding this Safety Recall, please contact your regional representative

VI. APPENDIX

1. CAMPAIGN DESIGNATION DECODER

E 0 Z

Year Campaign is Launched

8 = 2008 9 = 2009 A = 2010 B = 2011 C = 2012 D = 2013 E = 2014 F = 2015 Etc...

Repair Phase

1^st Campaign = A 2^nd Campaign = B 3^rd Campaign = C 4^th Campaign = D 5^th Campaign = E 6^th Campaign = F 7^th Campaign = G 8^th Campaign = H 9^th Campaign = I

Etc...

Current Campaign Letter for this year

0 = Remedy 1 = Interim (Remedy not yet available) “1”

will change to “0” when the Remedy is

available

Examples:

A0D = Launched in 2010, Remedy Phase, 4^th Campaign Launched in 2010 C1B = Launched in 2012, Interim Phase, 2^nd Campaign Launched in 2012 D0B = Launched in 2013, Remedy Phase, 1^st Campaign Launched in 2013